SpinMaster - BMSvision

SpinMaster
Real time production and quality monitoring
from fiber to yarn
To be successful in today’s demanding yarn market, modern spinning mills need to be fully
focused on performance and quality. Only spinning mills having real time production and
quality data for the entire production process can achieve an optimum relationship between
quality and efficiency.
With the SpinMaster system, BMS offers a solution for production and quality monitoring
covering the complete spinning mill.
Through a graphical user interface, SpinMaster users are constantly informed about the actual
situation in the spinning mill. Powerful analysis tools allow instant identification of poor
performing machines and spindles, resulting in a faster reaction to problems and an increased
efficiency and quality level.
EN product brochure A00523
SpinMaster: concept
Client computers
ERP Host
Tablets
OptiSpin/OptiTwist
Browser
Production
Reporting
Wireless router
TM
Wireless DU connection
Ethernet connection
Ethernet connection
SCU
OptiSpin
OptiTwist
Central unit
YarnMaster
WDL-Server
WEB-DU
Company
LAN
Windows server
SpinMaster
DU2P
DU9
DU9
Spectra
Zenit
Inputs/Outputs
Cards
Draw frames
Ethernet
Roving frames
Ring frames
Twisting machines
SpinMaster supports both cabled (Ethernet) and wireless networks
to connect the machines to the central server.
In case only machine based monitoring is required, the machine
is equipped with a BMSvision Data Unit for automatic as well as
manual data collection.
Connecting remote sites
SpinMaster supports the connection of multiple plants to one central
server. In the remote sites, M-Servers or WDL-Servers, connected to
the company’s intranet, link the machines to the central computer
system. A dedicated “multi-site consolidation module” on the
central SpinMaster server allows integrated reporting for all sites
into one single reporting environment.
Winders
SpinMaster is available for 64-bit Windows servers, both on physical
systems and in a virtualized environment. For clients, Windows 7, 8
or 10 is required, or Terminal Services can be used. The database
is Oracle driven.
Open End
ERP system integration
SpinMaster is easily integrated with the customer’s ERP system.
Through a standard interface, order and product data is transferred
from the ERP system and imported in the SpinMaster database.
The integrated export functionality allows a straightforward upload
of production data, calculated production schedules, work in
progress and performance indicators from SpinMaster to the ERP
system.
TM
System requirements
2
1N1
3N1
MFG/PRO
TM
Connecting machines to SpinMaster
Machine monitoring
In case only machine based monitoring is required, the machines are equipped with one
of the BMSvision Data Units: DU11, DU9 or DU2P. These units monitor the production
speed, production and stop time and automatic stops such as doffing, sliver breakage, ...
If stop time recorded as manual stop needs further analysis, the operator can enter the
exact stop reason.
DU11
The DU9 and DU11 are high end members of the BMSvision data collection terminals. The
DU9 features a 5” touch screen. The DU11 features a 7” touch screen and allows displaying various types of production documents. Both Data Units have a web based graphical
intuitive user interface. On screen language selection allows to switch between several
western and Asian languages on the spot. Both Data Units come with wired Ethernet as
well as the proven BMSvision Bluetooth based wireless network interface.
The DU2P has no screen and keyboard and is used in combination with the WEB-DU
for interaction with the operator. The WEB-DU application is used as HMI for a group of
machines and can be implemented on any browser enabled touch screen device such as
PC’s and tablets. The individual machines are equipped with a DU2P for automatic data
collection (production count and automatic stops) while all manual input and information
display is handled via the WEB-DU application.
Data Unit specifications:
Inputs/outputs
DU9
Networking
DU11
DU9
DU2P
Digital/counter inputs
16
8
4
Relays
5
5
-
Outputs (open collector)
-
-
1
Serial ports
2
-
-
USB ports
2
2
-
Ethernet ports
3
1
-
Wireless (WDL)
•
•
•
Wireless Ethernet (WLAN)
-
•
-
• (PoE)
• (PoE)
-
color
color
-
•
•
-
touch
touch
-
•
•
-
Wired Ethernet
User interface
Display
Touch screen
Keyboard
WEB-DU
Data integrity
Backup & Recovery
1
This option allows a minimum of 24 hours local data storage in case of server or network
breakdown.
1
Individual spindle monitoring: SCU
DU2P
On open end and texturing machines equipped with BarcoProfile, ring spinning machines
with OptiSpin and twisters with OptiTwist individual spindle monitoring, a touch panel based
industrial PC is used as Data Unit. All sensors on the machine are connected to this SCU
via a high speed databus.
The standard screen on the SCU shows a graphical machine view with color coded spindle
status and side by side machine details. Reports are available by shift and yarn lot.
SCU
BarcoProfile
OptiSpin
OptiTwist
3
Monitoring spinning equipment
Automatic data collection
Depending on the type of machine, various signals are available for automatic detection of production and machine status information. The
table below shows an overview of automatic detections for various types of machines in the spinning process.
Card
Drawframe
Comber
Roving frame
Ring spinning
Twister
Machine status (run/stop)
•
•
•
•
•
•
Delivery speed (m/min)
•
•
•
•
•
•
Spindle speed
•
Automatic
stops
Production (kg or m)
sliver break out
•
•
•
•
sliver break in right
•
sliver break in left
•
doffing
•
•
•
•
•
•
•
•
•
Available information
Depending on the type of machines, SpinMaster offers both tabular and graphical reports about the information as listed in the table below.
Card
Drawframe
Comber
Roving
frame
Ringspinning
Twister
Winding
Open end spinning
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Number of stops
Stop information
Stop time
(by stop reason)
Time/stop
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Machine efficiency
•
•
•
•
•
•
•
Production efficiency
•
•
•
•
•
•
•
Efficiency alarms and warnings
•
•
•
•
•
•
•
Chronological events (stop cause map)
•
•
•
•
•
•
•
Graphical plant overview
(PlantView)
Real time information
Machine status (run/stop)
Production (kg or m)
Spindle per spindle information
History reports (shift, day, week, month)
(tabular, graphs, trend reports)
4
•
•
•
•
1
Only with OptiSpin installed.
2
Only with BarcoProfile clearers (open end) or Loepfe YarnMaster (winding).
•
•
1
•
•
2
•
Spinning preparation and ring spinning
Efficiency trend by day
PlantView
Machine monitoring
The Data Unit on the machine detects delivery speed and automatic
stops such as doffing and hand stops. Additional information, such
as manual stop declarations, operator log on/off and other administrative data is entered via the Data Unit keyboard.
On the color coded layout of the mill, the frames are pictured in
certain colors, each color indicating the current machine status.
The user selects the type of information to be displayed: production
data, speeds, stop rates, efficiencies, ... User definable “filter sets”
allow the user to display only these machines that correspond with
a certain condition, for example all machines with an efficiency less
than 90%, all machines waiting for an intervention, ...
Every user, even without having any programming knowledge, can
define his own calculations and reports both in tabular and graphic
format by means of a built in report and formula generator.
Breakages in function of ring rail movement
OptiSpin sensors in action
Individual spindle monitoring
More and more spinning operations want to monitor the individual
ring spindle for yarn breaks and spindle speed. OptiSpin, based on
an individual optical sensor for each spindle, detects run/stop and
speed, monitors the ends down level and reports slipping spindles.
Connected to SpinMaster, a vast amount of additional information
is available in the database, which allows technicians to make a
detailed ends down analysis and improve efficiencies. One mouse
click on a particular ring frame allows the user to select any detailed
report, such as spindles with the highest breakage level, slipping
spindles per machine, yarn breaks as function of the bobbin build
up, during up and down movement of the ring rail, ... Stops are
always assigned to the right spindle, regardless the length of the
machine.
Ends down levels, slipping spindles, frame and spindle efficiency
are reported by doff, as well as by shift, day, week and month.
Trend reports highlight recurring problem spindles.
For a complete overview of our on-line quality monitoring system for ring spinning frames, please ask for our BarcoProfile brochure A00518.
5
OE spinning: OEMaster
Production monitoring
Loepfe clearers in action
SCU machine overview screen
OE machines require monitoring of the individual production points.
From each rotor, the following information is of importance to the
OE plant manager:
•
•
•
•
•
Run time and stop time
Number of yarn breakages
Number of yarn clearer cuts
Number of red lights and red light time
Number of doffings and doffing time
OE machines equipped with BarcoProfile, Corolab or Loepfe 1N1
and 3N1 yarn clearers can be connected to OEMaster without any
hardware cost involved.
For machines with another clearer, OEMaster offers a special
interface, called 3x4K, which is installed between the machine
information system and the yarn clearer system.
Q Quality monitoring
Beside the production and stop information, OEMaster also provides
all quality related information, such as:
•
•
•
•
•
•
•
Defect classification
CV% analysis
Spectrogram analysis
Sliver alarms and locks
IPI values and statistics
Moiré and pearl defects
CVL curves
Also the clearer settings can easily be up-and down loaded between
the central system and the yarn clearer system on the machine.
Spectrogram, CVL curve and histogram
Shift overview report
6
For machines equipped with ABS foreign fiber or Loepfe 3N1
clearers, foreign fiber related information such as number of
foreign fiber cuts per rotor and foreign fiber classification, are also
available in OEMaster.
For a complete overview of our yarn clearing and quality monitoring solution, please ask for our BarcoProfile brochure A00527.
Options
Incoming power for motor
Current transformers
DU9
Energy meter
Machine motor
Delivery speed sensor
Spindle speed sensor
Doffing rail sensor
Trend of electricity and compressed air consumption for a selected machine
Monitoring power consumption
Energy monitoring
With the EnergyMaster module, the SpinMaster system is extended
with a powerful tool to optimize the use of energy in the plant. Both
power meters and compressed air sensors on the machines can
be connected to the Data Units on the machines and consumption
data is passed on to the server using the SpinMaster data collection
network. Correlating the production data (Kg of yarn produced)
with energy consumption data allows the evaluation of the energy
component in the overall production cost of the order or product.
Production scheduling
The SpinMaster monitoring and reporting system can be extended
with a module for real time production scheduling. Yarn lots to be
produced are down loaded from the ERP system into the SpinMaster
database. By means of simple “drag & drop” the planner assigns
the production orders to the individual machines, using the electronic planboard.
Real time production scheduling
The Planboard is updated in real time according to the information
passed on by the monitoring system. Jobs which are too late are
automatically highlighted allowing the planner to take the necessary
actions to get the situation back under control.
For a complete overview of our energy management software, please ask for our EnergyMaster brochure A00622.
7
References
SpinMaster modular concept
Monitoring and reporting
Real time data collection
QMaster
Statistical quality control (SQC)
Report and formula generator
Key Performance Indicators (OEE)
Scheduling and order follow up
Real time graphical planboard
Ticket printing
Data import from lab equipment
Order status reporting
Quality management reporting
Yarn requirement calculation
Energy monitoring
Energy cost per style and order
MES database
Upload order progress
Climate monitoring
Upload production information
OEMaster
OptiSpin
Monitoring Open End machines
203272
Clearer setting management
Connects with Corolab and Loepfe
Download from orders and style data
Spindle by spindle monitoring
Real time yarn breakage detection
Traceability
Yarn breakage classification
From raw material to finished yarn
Trace back and forward
Where used
BMS bvba
BMS Vision Ltd
www.bmsvision.com
© Belgian Monitoring Systems
Member of the SavioGroup
BMSVision LLC
BMSvision China
Vlamingstraat 16, 8560 Wevelgem, Belgium
+32 56 262 611
+32 56 262 690
sales.bv@visionbms.com
Capricorn Park, Blakewater Road, Blackburn, Lancashire, BB1 5QR, United Kingdom
+44 1254 662 244
+44 1254 267 100
sales.bla@visionbms.com
4420 Taggart Creek Road, Suite 112, Charlotte, North Carolina 28208, United States
+1 704 392 9371
+1 704 399 5588
sales@visionbmsusa.com
Room 402, No.989, Dongfang Road, Pudong New District, Shanghai 200122, China
+86 21 6048 2876
gordon.guo@visionbms.com
A00523 05a EN 29/10/2015 DPD - Subject to change without prior notice. See www.bmsvision.com for the latest version.
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